08-JUL-2012
Removing the hump
I have a good tailgate but I don't want the hump so I decided to remove it. I was originally going to cut it out and weld a new piece in it's place but I found a nifty spot weld removal tool and went to work.
08-JUL-2012
Cutting the hump spotwelds
These spotweld cutters ranged from $9.99 to $60 online and that the more research that I read lead me to this one. It has a cutter head that is reversible, so basically two cutters for the price of one. What is even better is that it was only $3.99! I found the same cutter that people were selling for $9.99 on Ebay at Hardly Freight (Harbor Freight) for $3.99. I read the reviews online and people loved it so I picked one up from a local HF store and didn't have to pay shipping, another added bonus.
08-JUL-2012
The hump is removed!
This cutter worked perfectly. I zipped through 20 spot welds with ease, if you just go slow you won't burn up the cutter and the cheap thing should last a while.
08-JUL-2012
Hump is out
This hump came out quite easily and I will use it for the pattern for the new metal to be welded in place. I'll clean up the spot welds and the surface rust, prime it and weld a new flat piece in.
I think I will just tack it in with tacks all the way around instead of welding it all the way around. Welding it solid is not needed and it would surely distort and twist my nice tailgate.
Nice "flat" tailgate
This is what I what looking for, nice and flat. The nice big JEEP stamped in the tailgate is a nice touch on a flat tailgate. Now I have to go find a piece of sheet metal!
30-JUL-2012
Tailgate gets new sheetmetal
I went to my local metal supply today to find a piece of 16ga to fit my tailgate since I used all I had on the floor. The last couple weeks when I have checked the remnant section all they have had has been thin gauge like 20-22ga but today they had a couple pieces that were big enough to leave me some extra metal. So I walked out of there with the piece of sheetmetal that I needed and with $5.11 less in my pocket!
I cut it to size, primed the tailgate and the new metal edge, clamped it in place to get ready to weld it.
30-JUL-2012
All welded in
I felt that putting tack welds every 2" would work out good to hold the new metal in place. Everything was primed before welding so hopefully that will prevent rust from coming back.
30-JUL-2012
All welded in and flat
This side looks good and no more hump! When I spray the primer and top coat I will make sure that plenty of paint fills the edge and seals it.
10-JUL-2012
Drivers side rear damage
Next to do is the bodywork, most of the damage is in the back.
10-JUL-2012
Closer look at the drivers side
If I can get behind this panel I should be able to make it look half way decent.
10-JUL-2012
View of the lower section of the drivers side
I need to weld my stiffeners at the bottom here then move some metal outward!
10-JUL-2012
Passenger rear damage
I guess this guy liked to back into stuff!
This side is more crinkled that the drivers side. This is going to take some heat to straighten this out.